Service Procedure

NOTE
THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSION, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE, (I.E., EMERGENCY REPAIR) IS NOT REIMBURSABLE.

Examples of Ford products are: adhesives, sealers, solvents, cleaners, washes, and other special products listed in the Ford Car Care Products Manual.

NOTE
READ THIS REPAIR COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS.

CAUTION
TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND, AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURE. SEALERS USED IN THIS PROCEDURE SHOULD BE USED IN WELL-VENTILATED AREA.

1. Lower rear seats and open back panel compartments. Remove (2) rubber body plugs to perform the inspection procedure.





2. Visually inspect the underbody rear body mount # 3 area. Inspect the sheet metal on both right and left sides above the body rubber mount bushing, and at the area around the base of the upper washer for small hairline cracks. Cracks in this area may be the cause of the creaking noise (Figure 1).





3. Inspect the body welds above the rear RH and LH body mounts and look for any signs of stress cracks in this location (Figure 2).

a. If cracks are found or if reinforcement is separated, continue to Step 4.

b. If no cracks are found, inspect reinforcement from inside the vehicle to confirm that it is secured to the underbody cross member.

4. Remove the rear body mount bolts only. Keep the body mounts in place.

NOTE
BOLTS CONTAIN LOCTITE AND MAY REQUIRE UP TO 350 LB-FT. TO REMOVE.

5. Raise the vehicle to access the underside of the vehicle.

6. Remove both bed inner fender splash shields.

7. Remove the right and left side rear-most body side claddings.

NOTE
COMPLETE THIS REPAIR ON BOTH LH AND RH SIDES OF THE VEHICLE.





8. For cracks found in the underbody, drill the ends of any small cracks with a similar sized drill to prevent cracks from spreading (Figure 3).

NOTE
WELDING AND OR ADHESIVE SHOULD ONLY BE USED TO PREVENT REOCCURRENCE OF THE CRACKS AND IS NOT A REPAIR OPTION.

9. Apply Motorcraft TA-8 Super Seal Corrosion Protection material in and around this area. Keep any build up of this material to a minimum to allow the plate to seat properly.





10. With the entire vehicle properly supported (on large screw jacks), raise the rear of the cab from body mounts 9 mm to 13 mm (3/8 in to 1/2 in). Cab can be raised using the screw jacks placed under boxed section of the cab just forward of the rear mounts (Figure 4).

NOTE
USE CAUTION NOT TO OVER LIFT CAB AS THIS MAY CAUSE THE CAB FLOOR TO BE DISTORTED.

11. Insert the metal plate (1L54-35112A56-BA) in between the body and bushing. Short side of the plate is forward in vehicle position. To position, insert plates under the cab starting at the middle rear of the cab. After plate is under the cab, slide outboard into position.

12. Lower the cab. Make sure that the metal plate(s) are properly aligned. Install the two body bushing bolts and torque to 80 N.m (59 lb-ft). Make sure body mounts are properly torqued.

NOTE
OVER TIGHTENING MOUNT BOLTS MAY RESULT IN DAMAGE TO THE MOUNT BUSHINGS.








13. Drill four 6.5 mm (1/4") diameter holes, (2 in front and 2 in rear) into the sheet metal using the pre-drilled holes in the plate as a guide. The holes have to be drilled from the outside of the vehicle. The plate will locate itself after the plate is secured in Step 14 (Figures 5 and 6).

NOTE
THE REAR OF THE PLATE HAS FOUR HOLES.

USE ONLY THE 2 OUTER MOST HOLES AND THE 2ND INNERMOST HOLES ON EACH SIDE.

14. Visually verify that drilled holes are through both the cross sill and the reinforcement.

15. Apply Motorcraft TA-8 Super Seal Corrosion Protection material in and around the area of the drilled holes.

16. Install supplied rivets (4 per side) into the drilled holes and secure.

17. For the LH side (w/ the foot brake cable), relocate or remove the cable to improve drilling access.

18. Reinstall the body mount plugs.

19. Reinstall the torque box to frame bolts to 80 N.m (59 lb-ft).

20. Road test the vehicle to verify the effectiveness of the repair.

NOTE
SERVICE KIT 1L5Z-35112A56-CA CONTAINS INSTRUCTION SHEET, 2 REINFORCEMENT PLATES AND 8 RIVETS TO COMPLETE REPAIRS ON BOTH SIDES OF VEHICLE.